Garment with integrated reinforcement panels and method of manufacture

ABSTRACT

A garment and method of manufacture are disclosed. The garment is made from a plurality of material pieces and two reinforcement panels stitched together. The reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces. The reinforcement panels each include: an inner layer having an inner surface facing the wearer when the garment is worn, an outer layer having an exposed exterior surface and an opposite interior surface, a fusible layer bonded to the interior surface of the outer layer, and a batting layer between the fusible layer and the inner layer. The outer layer includes a plurality of rows of pintuck stitches on the exposed exterior surface or, alternatively, the outer layer, the fusible layer, and the batting layer are stitched together by a series of quilting stitches.

BACKGROUND

The present application relates generally to garments and, more particularly, to garments with integrated reinforcement panels to improve garment durability.

BRIEF SUMMARY OF THE DISCLOSURE

A garment in accordance with one or more embodiments includes a plurality of material pieces and two reinforcement panels stitched together to form a clothing article shaped to cover a portion of a wearer's body. The reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces. The reinforcement panels each comprise a plurality of layers overlaying one another, including: an inner layer having an inner surface facing the wearer when the garment is worn, an outer layer having an exposed exterior surface and an opposite interior surface, a fusible layer bonded to the interior surface of the outer layer, and a batting layer between the fusible layer and the inner layer. The outer layer includes a plurality of rows of pintuck stitches on the exposed exterior surface or, alternately, the outer layer, the fusible layer, and the batting layer are stitched together by a series of quilting stitches.

In accordance with one or more further embodiments, a method is disclosed for fabricating a garment, including the steps of: (a) forming a plurality of material pieces, each having a predetermined shape; (b) forming two reinforcement panels, each reinforcement panel comprising a plurality of layers overlaying one another, including: (i) an inner layer having an inner surface facing a wearer of the garment, (ii) an outer layer having an exposed exterior surface and an opposite interior surface, (iii) a fusible layer bonded to the interior surface of the outer layer, and (iv) a batting layer between the fusible layer and the inner layer; and (c) stitching the material pieces and reinforcement panels together to form a clothing article shaped to cover a portion of the wearer's body such that the reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces. The method may further include in step (b) forming a plurality of rows of pintuck stitches on the exposed exterior surface of each reinforcement panel or, alternately, stitching the outer layer, the fusible layer, and the batting layer of each reinforcement panel together by a series of quilting stitches.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 are front views of an exemplary pants having integrated reinforcement panels in accordance with one or more embodiments.

FIG. 5 is an enlarged view of a portion of the pants in FIG. 3 with portions of the reinforcement panel cut away for illustrative purposes.

FIG. 6 is an enlarged view of a portion of the pants of FIG. 2 with portions of an alternative reinforcement panel cut away for illustrative purposes in accordance with one or more embodiments.

FIGS. 7-12 are front views of portions of pants with alternate exemplary reinforcement panels in accordance with one or more embodiments.

FIGS. 13 and 14 are front views of exemplary tops having integrated reinforcement panels in accordance with one or more embodiments.

FIG. 15 shows an inside view of one front pant leg assembly to illustrate a process for constructing pants with integrated reinforcement panels in accordance with one or more embodiments.

DETAILED DESCRIPTION

Many garments, especially children's pants and tops, tend to rip easily at the knees or elbows after a few wears and washes. Various embodiments disclosed herein are directed to garments with integrated reinforcement panels to increase durability. The panels can be integrated in pant legs at the knee area or top sleeves at the elbow area. The integrated reinforcement panels increase the life and wear of the garments as well as provide improved comfort to wearers. The reinforcement panels are integrated in the garments, providing a stylish appearance.

The reinforcement panels can be integrated in a variety of garments including, but not limited to, pants (especially children's pants) long-sleeved T-shirts, long-sleeved sweatshirts, long-sleeved hooded tops (with or without a zipped front closure), and other tops.

FIGS. 1-4 illustrate examples of pants 2, 3, 4, 5, having integrated reinforcement panels 6, 7, 8, 9, respectively, in accordance with one or more embodiments.

FIG. 5 is an enlarged view of a portion of the pants 4 in FIG. 3 with portions of the reinforcement panel 8 cut away for illustrative purposes. As shown in FIG. 5, the reinforcement panel 8 includes four layers. An inner layer 14 is closest to the wearer when the pants are worn. The inner layer has an inner surface facing the interior of the pants and the wearer. An outer layer 16 has an exposed exterior surface and an opposite interior surface. A fusible layer 18 is bonded to the interior surface of the outer layer 16. A batting layer 20 is located between the fusible layer 18 and the inner layer 14.

The outer layer 16 can be made of a variety of fabrics (e.g., cotton, polyester, and other materials) that can be selected based on the quality and content of the style of the pants incorporating the panels. It is typically made of the same fabric as the garment's body fabric. In the FIG. 5 embodiment, the outer layer contains multiple rows of small pintucks 22, which are also known as keen pleating. The rows of pintuck stitching 22 are generally equally spaced. The pintuck stitched with can vary, e.g., from 1/16 inch to ⅛ inch. The pintuck stitching 22 is provided only on the outer layer 16 of the reinforcement panel. The pintuck stitching increases the durability of the outer layer 16 by making it more resistant to tearing. Additionally, it adds to the styling of the garment. Pintucking can be performed using, e.g., a Keen pleating machine.

The fusible layer 18 can comprise, e.g., an adhesive tricot interlining fusible that is heat sealed to the interior surface of the outer layer 16, after the outer layer has undergone the pintucking process. The fusible layer 18 provides strength to the outer layer 16, making the outer layer more resistant to stretching and tearing from abrasion.

Other fusible materials suitable for use in clothing can also be used including, e.g., a woven fusible, a knit tricot interlining fusible, or a polyurethane film. The fusible layer may incorporate a variety of adhesives including, e.g., dot lamination adhesive or a web adhesive. The fusible layer may have adhesive properties on one or both sides. Alternately, the fusible layer may have adhesive properties on one side and an abrasion resistant fabric on the other side. The fabric may be rigid or include stretch polymers. Additionally, the fusible layer may comprise a pre-laminated fabric with adhesive properties on both sides. The fusible layer may also comprise seam reinforcement tape, and can comprise one-sided or two-sided abrasion resistant laminate film.

The batting layer 20 can comprise a variety of batting materials including, e.g., a polyester, poly-fil batting. By way of example, the weight of the batting can range from 20-40 g/m2. The batting layer provides some cushioning or protection for the wearer's knees (or elbows in the case of tops). In addition, the batting layer enhances the appearance of the garment.

The inner layer 14 can be made of a variety of materials. However, it preferably comprises the same fabric as the garment's body fabric, and may be the same fabric as the outer layer 16.

Once the four layers are assembled to form the reinforcement panel 8, the panel is seamed into the rest of the garment. As shown in FIG. 5, the panel 8 is integrated in the rest of the pants by integrating seam 24 at the top of the reinforcement panel, integrating seam 26 at the bottom of the reinforcement panel and integrating seams 28, 30 which run along the sides of the reinforcement panel 8. These four seams join the four sides of the panel 8 to the rest of the garment, securing all layers of the panel to the garment. In FIG. 5, the panel is integrated at the knee area of the pant legs. A similar panel can be integrated at the elbow area of sleeves for garments that are tops.

The garments described herein involve reinforcement panels that are seamed into or integrated in the garments by being stitched at edges thereof to edges of one or more adjacent material pieces of the garments, rather than simply being layered over portions of existing garments. However, in one or more alternate embodiments, the reinforcement panels may be applied onto portions of existing garments.

FIG. 2 is a front view of another exemplary pair of pants 3 with alternative integrated reinforcement panels 7 in accordance with one or more alternate embodiments. FIG. 6 is an enlarged view of a portion of the pants of FIG. 2 with portions of the reinforcement panel 7 cut away for illustrative purposes in accordance with one or more embodiments.

Like the panel 8 shown in FIG. 5, the panel 7 of FIG. 6 includes four layers. An inner layer 36 is closest to the wearer, and can be the same as the inner layer 14 in FIG. 5. An outer layer 38 has an exposed exterior surface and an opposite interior surface. The outer layer 38 is different from the outer layer 16 of FIG. 5 in that it does not include pintuck stitching. A fusible layer 40 is bonded to the interior surface of the outer layer 38, and can be the same as the fusible layer 18 of FIG. 5. A batting layer 42 is located between the fusible layer 40 and the inner layer 36, and can be the same as the batting layer 20 of FIG. 5.

In the panel 7 of FIG. 6, the outer layer 38, the fusible layer 40, and the batting layer 42 are stitched together by a series of quilting stitches 44. The quilting stitches can vary and stitch design and/or stitch layout. A few non-limiting examples of possible quilting stitches are a diamond shaped pattern, a varying multi-needle straight stitch pattern, and a flower motif stitch pattern. The fusible layer 40 is bonded to the outer layer 38 before it undergoes the quilting process with the batting layer 42. The quilting increases the durability of the outer layer 38 by making it more resistant to tearing. Additionally, it adds to the styling of the garment.

Once the panel 7 is formed, it is seamed into the rest of the garment similar to the panel 8 in FIG. 5. In particular, the panel 7 is integrated in the rest of the pants by integrating seam 46 at the top of the reinforcement panel, integrating seam 48 at the bottom of the reinforcement panel and integrating seams 50, 52 which run along the sides of the reinforcement panel 7.

FIGS. 7-12 are front views of portions of individual pant legs with alternate exemplary reinforcement panels in accordance with one or more embodiments.

FIGS. 13 and 14 are front use of exemplary tops 54, 56 having integrated reinforcement panels 58, 60, respectively at the elbow areas of the sleeves of the garments in accordance with one or more embodiments. The reinforcement panels for the tops can be the same as or similar to the reinforcement panels described above for pants, and can be integrated in similar fashion.

The following illustrates one example of a process for manufacturing a pair of pants with integrated reinforcement panels in accordance with one or more embodiments.

The fabric used in constructing the pants is cut into a plurality of pattern pieces using standard pattern design and cutting techniques.

The fabrics and materials needed for the reinforcement panels are also cut, and the reinforcement panels are assembled as previously described.

Next, the pattern pieces and reinforcement panels are stitched together. First, the front of each pant leg is assembled. By way of example, FIG. 15 illustrates an inside view of one front pant leg assembly 62, which is comprised of three parts: a top pattern piece 64 (which extends to the waist), a reinforcement panel 66 in the center, and a lower pattern piece 68 (which is below the knee and extends to the hem). The reinforcement panel 66 is stitched to the top pattern piece 64 (with seam 24 shown in FIG. 5) and to the lower pattern piece 68 (with seam 26 in FIG. 5). The seams are straight stitch seams with a ⅜ inch seam allowance, and finished with a multi-needle overlock stitch to keep fabric from fraying. The assembled front legs are taken to a hot press/iron, where seams 24, 26 are pressed away from the reinforcement panel. The pressed seam allowances are then single needle straight stitched on the outside of the assembled front legs (an edge stitch).

The back of the pant (not shown) is also assembled in a standard process. For example, in the case of jeans, the pockets are stitched onto the back seat area of the pant and the top yolks are stitched onto the top portion near the waist with a flat feld seam. Once these operations have been performed for both back legs they are ready to be assembled to the front legs of the pants.

The inseam/seam at the inside of the leg is stitched first. This is seam 30 in FIG. 5. The seam 30 can be a single needle stitch or a multi-needle chain stitch. A ⅜ inch seam allowance is then finished with a multi-needle overlock stitch to keep fabric from fraying. The inseams are then pressed. In the case of a jean or Chino pant, the seams are pressed toward the back of the pants and then edge stitched at the front of the pants.

Next, both completed pant legs are assembled to each other at the rises. If the pant has a zipper opening, a zipper operation is done at this time. The seams are generally the same type of stitching technique as described above stitched and overlocked. In the case of jeans, the rises are flat feld seams, below the zipper fly.

Next the front pockets are constructed into the front of the pants near the waist.

The pants are then assembled at the side seams/outseams. This is seam 28 in FIG. 5.

In the case of a jean or Chino pant, the inside and outside of waistband are joined together at the top of waist, while the top of the belt loops are sandwiched between the layers. The jean and chino pant styles may have an adjustable waist feature, which is an encased specialty elastic that has buttonholes built into it. There is one button stitched onto the inside of the waistband near each end of the waistband. This allows for waist adjustments as needed for children having different sized waists. The waistband is then seamed onto the pant. The bottoms of the belt loops are then stitched onto the pant.

The hem of the pant is folded in at the top and then folded again and stitched with a straight stitch for a clean finish. This is called a double bend back hem.

Once the garments are completed, the styles that need washing are washed, dried, and pressed. The pants are then labeled and tagged. Some of the bulk then gets reviewed by a quality control team for make and measurement verification. Pants are then folded and bagged and are ready to ship.

Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present disclosure to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Additionally, elements and components described herein may be further divided into additional components or joined together to form fewer components for performing the same functions. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting. 

What is claimed is:
 1. A garment comprising a plurality of material pieces and two reinforcement panels, said material pieces and reinforcement panels being stitched together to form a clothing article shaped to cover a portion of a wearer's body, said reinforcement panels being integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces, said reinforcement panels each comprising a plurality of layers overlaying one another, including: an inner layer having an inner surface facing the wearer when the garment is worn, an outer layer having an exposed exterior surface and an opposite interior surface, a fusible layer bonded to the interior surface of the outer layer, and a batting layer between the fusible layer and the inner layer; wherein the outer layer includes a plurality of rows of pintuck stitches on the exposed exterior surface or wherein the outer layer, the fusible layer, and the batting layer are stitched together by a series of quilting stitches.
 2. The garment of claim 1, wherein the garment comprises a pair of pants having two pant legs, and wherein each reinforcement panel is located in a different one of the pant legs proximate a knee of the wearer when the garment is worn.
 3. The garment of claim 1, wherein the garment comprises an upper body garment including two long sleeves, and wherein each reinforcement panel is located in a different one of the long sleeves proximate an elbow of the wearer when the garment is worn.
 4. The garment of claim 1, wherein the garment comprises long pants, a long-sleeved shirt, a long-sleeved sweatshirt, a long-sleeved T-shirt, or a long-sleeved hooded top.
 5. The garment of claim 1, wherein the outer layer of each reinforcement panel comprises the same fabric as at least some of the plurality of material pieces.
 6. The garment of claim 1, wherein the inner layer of each reinforcement panel comprises the same fabric as at least the material pieces adjacent said reinforcement panel.
 7. The garment of claim 1, wherein the pintuck stitches have a width of 1/16″ to ⅛″.
 8. The garment of claim 1, wherein the fusible layer comprises an adhesive tricot interlining fusible material, a woven fusible material, a knit tricot interlining fusible material, or a polyurethane film bonded to the interior surface of the outer layer.
 9. The garment of claim 1, wherein the batting layer of each reinforcement panel comprises a polyester poly-fil batting material.
 10. The garment of claim 1, wherein the batting layer of each reinforcement panel has a weight of 20-40 g/m².
 11. A method of fabricating a garment comprising the steps of: (a) forming a plurality of material pieces, each having a predetermined shape; (b) forming two reinforcement panels, each reinforcement panel comprising a plurality of layers overlaying one another, including: (i) an inner layer having an inner surface facing a wearer of the garment, (ii) an outer layer having an exposed exterior surface and an opposite interior surface, (iii) a fusible layer bonded to the interior surface of the outer layer, and (iv) a batting layer between the fusible layer and the inner layer; and (c) stitching said material pieces and reinforcement panels together to form a clothing article shaped to cover a portion of the wearer's body such that said reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces.
 12. The method of claim 11, further comprising forming a plurality of rows of pintuck stitches on the exposed exterior surface of each reinforcement panel.
 13. The method of claim 12, wherein the pintuck stitches have a width of 1/16″ to ⅛″.
 14. The method of claim 11, wherein step (b) further comprises stitching the outer layer, the fusible layer, and the batting layer of each reinforcement panel together by a series of quilting stitches.
 15. The method of claim 11, wherein the garment comprises a pair of pants having two pant legs, and wherein each reinforcement panel is arranged in a different one of the pant legs proximate a knee of the wearer when the garment is worn.
 16. The method of claim 11, wherein the garment comprises an upper body garment including two long sleeves, and wherein each reinforcement panel is arranged in a different one of the long sleeves proximate an elbow of the wearer when the garment is worn.
 17. The method of claim 11, wherein the garment comprises long pants, a long-sleeved shirt, a long-sleeved sweatshirt, a long-sleeved T-shirt, or a long-sleeved hooded top.
 18. The method of claim 11, wherein the outer layer of each reinforcement panel comprises the same fabric as at least some of the plurality of material pieces.
 19. The method of claim 11, wherein the inner layer of each reinforcement panel comprises the same fabric as at least the material pieces adjacent said reinforcement panel.
 20. The method of claim 11, wherein the fusible layer of each reinforcement panel comprises an adhesive tricot interlining fusible material, a woven fusible material, a knit tricot interlining fusible material, or a polyurethane film bonded to the interior surface of the outer layer.
 21. The method of claim 11, wherein the batting layer of each reinforcement panel comprises a polyester poly-fil batting material.
 22. The method of claim 11, wherein the batting layer of each reinforcement panel has a weight of 20-40 g/m².
 23. A garment made by the method of claim
 11. 